Monolothic refractories

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GOVERNMENT INSTITUTE OF CERAMIC
TECHNOLOGY
GUDUR, NELLORE (D.T), A.P, INDIA
PROJECT REPORT ON
TESTING
OF
MONOLITHIC REFRACTORIES
SECOND SPELL IMPLANT TRAINING
IN

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DURING TRAINING PERIOD: 16.12.09 TO 15.06.10
SUBMITTED BY:
S.DILEEP
PIN NO: 07070-CER-010
CONTENTS
 ACKNOWLEDGEMENT
 PLANT INTRODUCTION
 MANUFACTURING
1. MONOLITHICS
2. PRECAST
 LABORATORY/TECHNICAL
 SAFETY MEASUREMENTS

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ACKNOLEDGEMENT
I am grateful thanks to Mr. T.ANTONY. (GENERAL
MANAGER -OPERATIONS) for giving me an opportunity to do in-
plant training in VESUVIUS INDIA LTD in VISAKHAPATNAM.
I am also grateful thanks to
1. Mr. PARTHA SARATHY
MUKHOPADHAYA (PRODUCT DEVELOPME
MANAGER)
2. Mr. SAUGATA DATTA (TECHNICAL MANAGER)
3. Mr. SIBAPRASAD PATNAIK (QUALITY ASSURANCE
INCHARGE)
4. Mr. GOVINDA RAJU (HRD OFFICER)
I am thanksful to all the executives and operatives for
being coordinate to me while doing my training.

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I was associated with VESUVIUS team for six months and
it was a great pleasure in working in a friendly atmosphere.
INTRODUCTION:
VESUVIUS is a worldwide leader in developing, manufacturing
and marketing high performance refractory products for demanding
Industrial applications. Its major customers are in the steel, ferrous and
non-ferrous foundries, and glass industries. Vesuvius India Ltd is three
divisions one is Vesuvius, kolkata which is producing flow control
modifiers and sub entry nozzles. And another is at mehasana, which is
producing crucibles.
Quality of service and a wide range of products has always been part
of VESUVIUS corporate strategy to delight its customers.
VESUVIUS has started producing monolithic in the year of 2001 in
Vizag. They manufacture monolithic refractories and pre fired precast
shapes these products are used in Metallurgical, chemical and power
sector industries.

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COOKSON
Precious metals ceramics electronics
Vesuvius international
Kolkata Visakhapatnam mehasana
Monolithics precast
Flow control Castables pre cast shape and crucibles
taphole clay

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Customers
MONOLITHICS:
Monolithics is an unshaped refractory mixture, which are more
than improved properties, compared to other refractors as per physically
and also chemically better properties.
Advantages of monolithic Refractories
 Since no shaping and firing is involved, the manufacturing and
delivery times are shorter, and the user requires fewer inventories.
 Since no firing is involved a sufficient amount of energy is saved
and expensive pollution-control devises for furnace exhaust gasses
are not needed.
 The building of efficient furnaces often involves larger,
complicated shapes to achieve the desired performance which
needs costly skilled labor and takes longer time to complete.
Monolithic refractories, on the other hand, involve simplified
construction for complicated structure. Monolithic refractories can
be applied using various methods depending on the types of
application.
 Monolithic refractories linings are usually thinner than the
corresponding brick structure. They are more durable since
building with bricks involves the use of mortars to joint the brick

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together, thus creating weak points in the structure. Monolithic
refractories can be built around supports and may not need to be
self-supporting in applications such as thick brick arch linings
 Monolithic refractories can be repaired locally with out disturbing
the whole structure, thus saving material time and labors.
CLASSIFICATION OF THE UNSHAPED REFRACTORIES:
1. Refractory mortars
 Air setting mortars
 Heat setting mortars
 Special mortars
2. Refractory Castables
 Low cement castables
 High cement castables (conventional castables)
 Ultra low cement castables
 No cement castables
 Modern castables
 Basic castables
 Self flow castables
 Gel bonded castables
3. Ramming masses
 Dry ramming masses
 Anhydrous dry raw material
 Induction basic raw material
1. Moist ramming masses
 Tap hole mass
 Blast furnace through mass
4. Refractory plastic masses

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 Pre mixed wet raw material
 Dry plastic material mixed at site.
5. Gunning mixes and other repair masses.
 Hot gunning
 Fettling & spinning
 Tundish coating spraying masses.
 End less lining
CLASSIFICATION OF THE MONOLITHICS REFRACTORIES:
The unique method of casting by the method of casting by the
method of ramming, vibratory, gunning of a refractory aggregates,
cement and adding of some binders or water and then cast in a mould
cavity is known as castables. Those are classified into as follows.
A. By using their application
 Self flow castables
 Gunning castables
 Gel bonded castables
 Ramming refractory
 Plastic refractory
 Vibrate castable refractory
 Dry veritable
 Pumpable refractory
 Refractory mortars
 Injectable refractory
 Spraying
B. By the basic content of cement content
 High cement castables (conventional castables)
 Low cement castables

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 Ultra low cement castables
 No cement castables
Low cement castables:
Low cement castables contains 5-8% of high alumina
cements. It has low porosity, high strength. And also less water demand
for casting. Low cement castables service range up to 1500-1800°c.
Low cement castables exhibits superior properties compared to
conventional castables products will have higher porosity than lower
cement castables. In steel industries applications, the higher porosity
allows slag & molten iron effectively surface. This can be reducing by
proper grading of refractory grains. As bond the refractory material
losses and also its strength.
Applications of low cement castables:
 Tundish safety linings (backup lining)
 Low cement castables for cast repairs of low iron ladles.
 Low cement castables for steel ladle applications including sub
bottoms, working bottoms and lip rings.
 Torpedo ladle parts
1. Cone end safely
2. Throat
 Iron ladle sidewall impact.
 Back lining of troughs
 Soaking pit covers.
 Sintering furnace roof

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 Hearth or re-heating furnaces
 Rotary kilns (various zones)
Conventional castables:
Conventional castables contains 8-20% of high alumina
cements. This product requires High water demand and also has more
porosity.Conventional castables comes under Insulation castables.
Ultra low cement castables:
Ultra low cement castables contains high alumina cements
less than 3%. Withstand from rapid heating and cooling.
Application of ultra low cement castables:
 Ultra low cement castables for cast repairs of iron ladle.
 Ultra low cement castables for the harshest of steel ladle
applications including sub bottoms, working bottoms and lip
rings
 The lining of blast furnace troughs mainly.
No cement castables:
No cement castables also allowing same properties related to
cement and hydratable alumina products. No cement used in it. No
cement castables have excellent flow behavior, hot strength and thermal
shock résistance and are for giving in tough dry out applications.

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CLASSIFICATION OF SHAPED REFRACTORIES
Refractory can be classified on the basic of various criteria but the
common practice it dependent up on the chemical nature these are
basically three types
1. ACIDIC 2.BASIC 3.NEUTRAL 4.SPECIAL
RAW MATERIALS USED FOR THE MANUFACTURING OF
MONOLITHIC REFRACTORY:
1. ALUMINA
 Bauxite
 Sintered alumina
 Calcined alumina
2. ALUMINA SILICATES
 Kynite
 Siliminate sand
ACIDIC BASIC NEUTRAL SPECIAL
Fire clay Magnasite Chromite High alumina
semisilica dolomite graphite silicon carbide
Silica Chrome-magnesite Carbon High silica
magnasite-chrome Zirconia’s ceramits
Zircon fused cast
refractories

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 Andalusite
 Mulcoa
3. SILICA BASED
 Quartz sand
 Fused silica
4. ZIRCON SAND
5. CHROME SAND
6. CARBON BASED
 Coltar pitch
 Carbon block
7. CLAYS
 Ball clay
 Bentonite
8. INSULATING MATERIALS
 Insulating grog
 Perlite
 Vermiculate
 Bubble alumina
ALUMINA:
 Bauxite:
Bauxite is hydrated alumina material. Its chemical formula is
Al2O3 2H2O.Bauxite has the nominal composition,75% of Al2O3.It is a
medium soft to rock,has a cellular,porous or fine grained compact
structure,conchoidal or uneven structure,and ranges in color from light
gray cream,yellow to dark brown.The Bauxite tends to rich alumina.
For done by the process of Bayer process.It is mainly increases the
percentage of alumina content in material.Bauxite has 75-90% of Al2O3
before calcinations. After calcinations it will increased up to 90-95%of
Al2O3
 Calcined alumina:

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It is prepared from bauxite, which is containing large
impurities by applying Bayer process. Simply it is Bauxites heated in
pressure vessels with sodium hydroxide solution at 150-200°C
through which alumina is dissolved as acuminate in Bayer process.
Ferruginous matter reduce (red mud) by filtering, pure gibbsite
precipitated when the liquor is cooled and seeded with fine-grained
aluminium hydroxide. Gibbsite is converted in to aluminium oxide by
heating. This is molten approx 1000°C by addition of cryolite as a
flux. It is subjected to further purification to removal of trace Na2o.
 Sintered alumina:
Sintering! The alumina calcined at the temperature of around
2000°C,then which has been formed in to balls, makes sintered alumina.
In generally this is sintered in rotary kiln and later this is crushed and
classified according to grain size. This is also called as Tabular alumina.
1. White fused alumina:
Manufacturing of white fused alumina by completely melting
of alumina in arc furnace or otherwise in electrical furnace. After that
crushed in to different sizes according to required sizes.
2. Brown fused alumina
Completely melting of bauxite, Anthracite and iron makes
brown fused alumina. Iron will be at a range of 1.7-2.5%
2. ALUMINO SILICATES:
Silimanite sand:
The chemical formula is Al2O3 SiO2. The color of the silimanite
may be grayish brown,grayish green and occur in fibrous masses
usually in the form of bundles of thin slender crystals. It is as well
Alumina silicate Refractory raw material. The silimanite decomposes
when heating at the temperature of 1530°C-1625°C. Density is
3.20gm/cc. The crystal system of it is Orthorhombic.

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Andalusite:
chemical formula is same as sillimanite(Al2O3SiO2).It occurs
as gray to steel gray idiomorphic crystals with orthorhombic habit in
argillaceous slated and schists. This mineral has same composition of
same sillimanite and kyanite. Andaulusite forms a tri morphic series.
It contains a density of 3.0-3.2 gm/cc
Kyanite:
Chemical formula is same as of sillimanite and
andalusite(Al2O3SiO2).Kyanite occurs usually as long and short
bladed and tabular crystals; and the color is light yellow and grayish
white.The mineral shows the volume expansion on heating.It has
sp.gr of 3.6.
Talbaster clays:
Is a material contains alumino silicates. It is naturally
available and also it is having some impurities in it. The chemical
formula is also same for pyrophillite clays(Al2O3 4SiO2 H2O), but
before using it to be calcined for the separation of molecularly
combined water.
Pyrophillite clays:
It is also contains alumino silicates. It is purify than compared
to talbaster clays.
 Chemical formula- Al2O3 4SiO2 H2O
 Alumina% - 40-44%
 Lower thermal expansion.
 Density - 2.70-2.80 gm/cc
 Mulcoa:
It is not naturally occurring material. It is prepared by melting
of purified alumina and silica at around 1500C forms likes rolls.
Those are crushed according to their sizes. Its chemical formula is
3Al2O3 2SiO2. Its melting point is 1810°C and its density is 2.9-3.0
gm/cc.
3.SILICA BASED :

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1. Quartz sand
Quartz sand it is formed from the quartzite rock and silica sand.
This quartz has consisting of 99% SiO2.The color of this is in white
with free flow.
It is made by mechanically crushing sand stone and quartzite. It
has a melting point of 1726°C. The density is 2.65gm/cc and the
hardness as per Moh`s scale 7.
2. Fused silica
Fused silica is also called as fused quartz. It consists of
amorphous silica glass. This material is artificially manufactured by
the fusion of high purity silica at the temperature of above 1700°C.
Properties:
 Melting temperature- 1728°C.
 Low thermal expansion.
 Excellent resistance of corrosion.
3. Silicon carbide:
Silicon carbide (sic) is highly wear resistant and also has good
mechanical properties, including high temperature strength and thermal
shock resistance. It is an artificial raw material. It is made by heating
silica sand and petroleum coke packed around carbon electrodes in an
electric resistance furnace to above 2200c. The process for making is
complicated. It includes vapor solid reactions. The formation is as
follows.
SIO2 + 3C SIC + 2CO
It is harder than corundum, which is having the hardness number 9
according to moh’s scale. It is resistant to abrasion, corrosion to slag
attacks. Thermal expansion is low; hence thermal conductivity is high it

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can easily oxidise when in oxidizing atmosphere the reaction will start at
the temperature of 800c. In a reducing atmosphere it will start that
decompose at the temperature of 2000c.
ZIRCON SAND: Its chemical formula is Zrsio4.zircon has high
temperature resistance (melting point is 2500c) corrosion resistance,
high thermal conductivity and low thermal expansion.
The availability of zircon sand is generally sea source or riverbeds. It is
available in the size of 3mm or less in grain size. The density is 4.56
gm/cc.
INSULATING MATERIALS:
BUBBLE ALUMINA:
The bubble alumina is a hallow spherulitic heat insulation material.
Alumina is melted to the melting temperature, which is made by
electro fusing method. By blowing a steam of air with high pressure
into the molten alumina. That will become in the bubbly structure. It
having specific gravity is 3.90.It is having 99 % of Al2O3.
VERMICULLITE:
Vermiculite is a three-layered structure with Mgo 6H20 between sheets.
When Vermiculite is heated at around 350ºc begins to shrink. At above
400º c water releases and exfoliates. In the process Vermiculite will
swell up to 10-20 times its original volume. Exfoliated Vermiculite has a
poor strength but very low thermal conductivity.

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Chemical formulae:22Mgo 5Al2O3 22SiO2 4H2O
Color :Brownish
CLAYS:
Ball clay:
Ball clay is plastic sedimentary clay. The color is light
yellowish. It contains 85% finally colloidal particles more than 1
micron. It’s contains high shrinkage and high strength. It consisting a
good workability.
Chemical formulae:Al2O3 2SiO2 2H2O
Bentonite clays:
Its chemical formula is Al2O3 4SiO2 9H2o. Bentonite is a
natural inorganic material composed from chiefly of montmorillonite
type of clay materials and usually derived from volcanic ash. It is
enhancing the plastic property.
MINOR INGREDIANTS:
CHROMIUM OXIDE: chromium oxide structure is similar to
corundum structure. CUBIC close packed oxide 2/3rd of the octahedral
holes occupied by chromium. it is green color. It’s having more specific
gravity 5.22 gm/cc. Its melting point is 2435c. Boiling point is 4000c
for the advantages of using this material using in castable to increase the
Non-wet ability property of the product. Its PH value is between 6-9.its
averages chemical composition is as follows.
CR2O3 - 98.5%
Fe2O3 - 2%
MGO - 2%
AL2O3 - 2%
HYDRATED LIME: it is used for the purpose of quick setting. In this
material having CaO
CITRIC ACID: It is used as to maintain the constant flow in a product.
And it is used as a salt retarder in 45-75% of alumina castables.

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SEA WATER MAGNESIA: the appearance is dull white fine powder.
It is having 99% of Mgo and it is used in no cement castable in place of
cement.
SULPHUR: to use this material in refractories gives more resistance to
the carbon monoxide.
STPP: It means sodium tri poly phosphate. It is a binding material and
suspending agent. It’s also known as HCBS (highly concentrated
ceramic binding suspensions) the advantages are reducing water
demand, decrease porosity and increase strength in ceramic Castables.
For the purpose of increase the flow of the product.
The following minor ingredients are used. These are used according to
the using of raw materials in the product.
i. Calgon`s
ii. Dispex
iii. Boric acid
iv. Borax
ORGANIC FIBER: it is using the purpose of reinforcement between
the particles.
ULTRAZIN Na: purified sodium ligno sulphonate with high average
molecular weight & potent dispersing efficiency dispersant for wet table
powder. Used in the gunning castable for the bonding purpose.
ALUMINA METAL POWDER: in explosive sapling during castable
dewatering oxidation of coke or graphite at high temperature in carbon
containing materials. Increase permeability of the castables. Minimum
amount of alumina reacts with H2O during process. Metal in
microstructure prevent carbon oxidation.
FLUORSPAR: It appears like white fine powder.
Its chemical formula CAF2
Its melting point 1270 to 1387c
Its average chemical composition is
CAF2- 95%, SIO2- 3%, CACO3- 1%, Fe2O3- 0.12%

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ALUMINA BASED RAW MATERIALS THEIR COLOUR AND
% OF Al2O3
RAW MATERIALS COLOR
%OF
AI2O3
ALUMINA BASED MATERIALS
WASHED BALLCLAY DRY WHITE 15
BENTONITE DARK YELLOW 32
HYMOD EXCELSIOR DRY GRAY 35
CHINA CLAY LIGHT WHITE 38
TALBASTER CLAY CREAM 40
CALCINED PYROPHILITE CREAM 44
CALUNDUM DULL BROWN 48
ALUMINA GROG DULL GRAY 46-52
RAW KYANITE (INDIAN) WHITE, REDDISH
WHITE
58
MULCOVA DARK BROWN 58
REFCEM60 LIGHT GRAY 59
SILIMINITE SAND LIGHT GREENISH 59
DURANDAL PINKISH 59.5
ANDALUSITE BROWN 60.9
TABULAR ALUMINA WHITE 99
KERPHOLITEFINES BROWN 60.9
HIGH ALUMINA GROG DULL GRAY 65
SEACAR 71 DULL WHITE 72
SPINEL AR78 WHITE 77
SEACAR80 DULL WHITE 79
CA25R DULL WHITE 80
SHAFT KILN BAUXITE
BLACK TO DULL
BROWN 88
ROTARYKILN BAUXITE
BLACK TO DULL
BROWN 88
ULTRA D ROUND KILN BAUXITE
BLACK TO DULL
BROWN 89
ALPHASTER BAUXITE
BLACK TO DULL
BROWN 89.5

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REFRASTER BAUXITE
BLACK TO DULL
BROWN 90
SPINEL AR90 WHITE 90
C.B FINES (BROWNFUSED DUST
COLLECTION)
LIGHT BROWN 91
BROWNFUSED ALUMINA BROWN 94
BROWNALOXIDE ABMC GRAYISH
BROWN
95
WHITE FUSED FILTERFINES WHITE 97
WHITE FUSED DC FINES WHITE 98
FUSED ALUMINA WHITE 98.7
WHITE FUSEDALUMINA WHITE 99
MRB 01 MILK WHITE 99
CALCINED ALUMINA MR301 WHITE 99.2
A 17 NE ALUMINA MILK WHITE 99.2
NSPL 20 WHITE 99.5
INDAL S WHITE 99.5
HGRM 30 99.5
CTC20 MILK WHITE 99.7
REACTIVE ALUMINA CT4000 WHITE 99.8
CTC40 MILK WHITE 99.8
CT9 FG MILK WHITE 99.8
CL 370C MILK WHITE 99.8
MINOR INGREDIANTS
ALUMINIUM METAL POWDER GRAY
BARIUM SULPHATE WHITE
BORIC ACID WHITE
BORAX WHITE
BUDAPUR WHITE
CALCIUMFLURIDE WHITE
CALCITE POWDER WHITE
HEXAMETA PHOSPHATE WHITE
CALGON(DISPERSANT) WHITE

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CITRICACID WHITE
CHROME OXIDE GREEN
DISPEX WHITE
FABUTIT WHITE
GALORIL
WHITE
HYDRATED LIME WHITE
PEAKSTONE LIME WHITE
SILUBIT YELLOW
SODIUM TRYPOLYPHOSPHATE WHITE
SULPHUR POWDER YELLOW
ANDALUSITE DARK BROWN
COLLOIDAL SILICA WHITE
DEXTRINPOWDER WHITE
PHOSPORICACID WHITE
LIQUID SODIUMSILICATE WHITE
ULTRAZINE NA WHITE
COALTARPITCH WHITE
METALURGICALCOKE DUST BLACK
COALTARPITCHPELLET BLACK
CHROME SAND BLACK TO
BROWNISH
FIBRE WHITE
FELDSPAR WHITE
FLUORSPARACID WHITE
SILICONCARBIDE BLACK
ZIRCONSAND LIGHT BROWN
QUARTZ SAND DULL WHITE
SILIMINITE SAND
BROWNISH
TO LIGHT
GREENISH
VERMICULITE REDDISH

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FLOW SHEET FOR MANUFACTURING OF MONOLITHIC
REFRACTORIES
Raw material receiving
Storage in racks
Silo selection
Charging into silos
Vibro feeder (coarse) screw feeder (fines)
Addition of minor ingredients
Discharging in to weigh hopper
Charging into mixer
Mixing (five minutes)
Discharging in to ton bag
Lab testing
Packing (1 MT) bagging machine
Dispatch Bagging
Dispatch

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PRODUCTION AND MANUFACTURING PROCESS FOR
CASTABLES:
Raw materials are received and kept in designed racks. Raw materials
are received in different quantities of bags that were changed into in
one-ton bag. Because of easy charging. After those bags are send to
charging as follow as charging scheduler. Then the materials are placed
in lift for silo charging. As per charging scheduler the raw materials are
charged into represented silos. In this plant total 24 silos are for 2
mixers. These 24 silos are divided into twelve-twelve silos. Twelve silos
are comes system-I, and another twelve silos are comes system-II. Two
types of feeder are used in every system it’s depend upon material size,
behavior of feeding.
AUTOMATIC BATCHING SYSTEM:
Automatic batching will do by using PLC system. After charging of
materials, download the recipe as per given in technical department.
After downloading the recipe to press the batch start and it automatically
batching will done. The material quantity knowing by using weigh
hopper the batch will comes to weigh hopper.
Weigh hopper to get accurate weight, calibration will do. Weigh hopper
contain gate because to stop the material as reach required quantity.
After reaching of material the gate automatically opened. At the same
time minor ingredients to be added the batch. Because to get required
properties.
After batching the batch goes to mixer by using screw conveyor the
screw revolves opposite direction the batch goes to mixer, for mixing.
Mixing will done in five minutes. After mixing the screw revolves right
side the material discharged into a ton bag. From the batching ton bags
5kgs of sample material take to in lab for tests. After testing of quality

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control the material will packed in to required quantity as per customer
requirement and dispatch it.
FLOW SHEET FOR BATCHING
Raw materials
Placed in lift
Recipe entry from the technical department
Silo selection
Charging into silos
Automatic batching system
Batching
Weigh hopper Addition of minor
ingredients
Mixer
Mixing (five minutes)
Discharge into ton bag
Lab testing
BAGGING:
After discharging of material the material will collect in ton bag. As per
customer requirements we do bulk or small quantity, around 50or25 kgs.

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We want bulk type we collect jumbo bag. After completion of quality
test we dispatch it. We want small quantity of bags we done as follows.
Mixer discharging material we collect in to ton bag. The ton bag is
charged into bagging hopper by using EOT crane. In bagging machine
contain one control panel it will first enter the required quantity of
product. After start bagging machine it collect in bottom with bag.
Bagging machine contain one load cell. It acts as to fill accurate weight
as enter in control panel. After collecting of material that was stitched
into stitching machine. Later the bags placed in pallet and dispatch it.
FLOW SHEET FOR BAGGING MACHINE
Discharge into mixer (MT bag)
Bulk type (1000kgs) FOR small quantity (50,25)kg
In MT bag In MT bag
Quality control EOT crane (For
lifting)
Packing Charging into hopper
Dispatch Bag fixing
Material filling
Conveyor belt
Stitching
Removing
Pallet spacing
F.G racks
Dispatch

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Pre cast
Precast are the casted shapes with castables in predetermined
moulds by adding of water or binder. Generally the castables are high
cement castables, low cement castables, ultra low cement castables and
no cement castables. These are prefired prior to application. Precast
shapes are generally meant for ladle and tundish furniture in continuous
casting of steel. And also used in non-ferrous industries like aluminum,
copper industries and also in power and petro chemical industries. The
all shapes manufactured in pre cast are by the customer’s specification
and their requirements.
These are pre-fired in shuttle kilns. In this kilns having cars. After
de molding, air curing the shapes is loaded on the cars. After that the car
is sent into kiln or ovens. For the firing will be programmed. The
program is maintained by PLC. After the finishing of program it cooled
in kiln or ovens. After cooling in air those are inspected by visually then
it is sent to dispatch.
In precast these commonly shapes are given below.
Weirs
Impact pads
 Well blocks for ladle and tundish
 Housing blocks
 Dams
 Blocks
 Flow modifier
 Tap out blocks
 Launder

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 Inner nozzle
Precast manufacturing process
Mould assembling
Applying of lubricants
Water addition Castable mixing
Casting
(Generally vibro casting)
Air curing (for setting)
De molding
Air curing
Firing
Quality inspection
Dispatch

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LABORATORY
EQUIPMENTS USED IN LABORATORY:
Vesuvius India LTD laboratory at Visakhapatnam is one of the
well-equipped laboratories for testing of monolithics. Hear following
testing equipments are available.
SIEVE SHAKER: to determine the particle size distribution of the raw
materials and products
MOISTURE ANALYZER: to determine the moisture content in the
raw materials and products
BROOK FIELD VISCOMETER: it is used for the determination of
viscosity of all liquids
MAGNETIC ANALYZER: for the determination of the free magnetic
iron in raw materials and products.
HOBART MIXER: it is used for the wet mixing of the monolithic
products.
PLATFORM VIBRATOR: it is used for determination of flow ability
of monolithic product and also fabrication of the test specimen.
DRIER: it is used for determination of test specimens at 110c

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FURNACE: it is used for the firing of test specimens. In this plant the
following furnaces are there.
HOT MOR FURNACE (hot modulus of rupture): it is used for the
determination of HOT MOR at desired bars at desired temperature
SPALLING RESISTANCE: it is used for the determination of spalling
of refractory brick at required temperature.
PCE FURNACE: it is used for the determination of PCE (pyrometric
cone equivalent) for each refractory material. PCE values refer the
refractoriness of the product.
THERMAL CONDUCTIVITY FURNACE: it is used for the
determination of thermal conductivity of refractories.
INDUCTION FURNACE: it is used for the determination of slag
corrosion attack of the refractories.
ABRASION TESTER: it is used for the determination of abrasion
resistance of refractories.
UTM (UNIVERSAL TESTING MACHINE): it is used for the
determination of cold MOR and CCS of the cast samples. There is two
UTM machines are available.
 One is maximum 400 KN capacities for the cold MOR and CCS of
products. (Digital type)
 Another is 25KN capacity for the cold MOR and CCS of light
products. (Digital type)

30. 30
TEST CONDUCTEDIN LABORATORY :
MOISTURE CONTENT:
SIMPLEST METHOD:
The percentage of moisture present in a material is known as
moisture content of a material. To determine the moisture content in raw
material.Is to weigh a sample of the material(W1),and then heated in a
oven at the of 110oc and re-weigh(W2). Calculation of moisture content
is as follows.
Initial weight (W1)-dry weight (W2)
% of moisture content = X 100
Initial weight (W1)
MOISTURE ANALYSER TESTING MACHINE:
Moisture content of a material can be directly determined in the moisture
analyzer. The moisture analyzer shows the result directly in percentage.
This instrument is very suitable for ceramic raw materials.The
entire sequence of drying and moisture extraction is carried out on the
balance it self and the moisture content is automatically reading on the
display.
Moisture extraction is effected rapidly by an lamp that can be
adjusted for height over the balance pan.The pan is loaded with
sample,then switch on during evaporation of water,the scale pointered
continuously records the percentage of water removed from the sample
records on the pointer reading become constant the test completed.
PARTICLE SIZE ANALYSIS: Conformity of the particle size
distribution is more important after crushing or grinding. Determination

31. 31
of particle size is two types. One is dry sieve analysis and another is wet
sieve analysis.
Procedure: Using vibrating sieve shaker the particle. Size distribution
will be determined. The sieves are arranged as a stack as per
specification with the coarsest sieve top and finest sieve bottom. Take
100 gm of material put it for sieve and then stack is placed on vibrate
table. Fix the lid set vibration and its time after completion of vibration
remove stack from vibrate table and weigh the material retain on each
sieve in the weighing balance (accuracy of 0.01 gm)
PERMEANENT LINEAR CHANGE (PLC): The permanent change
in length due to application of elevated temperature is known as
permanent linear change. Generally after drying of ceramic products
specimens measure initial length (L1). After that specimens introduced in
the furnace. The elevated temperature is programmed. After finishing the
programmer it is cooled to room temprature, then measure the length(L2)
due to firing some of the shrinkage and expansion will occur in the
products.
If the result is in negative the specimen will shinked if result is in
positive the specimen to be expanded. The result is calculated as
follows.
Formula: the PLC of the product depends upon the composition and
firing schedule of the product.
Final length (L2)-initial length (L1)
% Of PLC = X 100
Initial length (L1)
Permanent linear change of some monolithic products.
HIGH ALUMINA LOW CEMCNT CASTABLE
PRODUCT P.L.C% AT 1000°c
45% H.A.L.C.C. -0.34
50% H.A.L.C.C. -0.13
60% H.A.L.C.C. -0.11
70% H.A.L.C.C. -0.25
80% H.A.L.C.C. -0.03

32. 32
90% H.A.L.C.C. 0.21
HIGH ALUMINA HIGH CEMENT CASTABLE
PRODUCT P.L.C %AT 1000 °c
90% H.A.H.C.C. 0.154
80% H.A.H.C.C. 0.18
70% H.A.H.C.C. 0.2
60% H.A.H.C.C. 0.21
50% H.A.H.C.C. 0.25
45% H.A.H.C.C. 0.29
Permanent linear change at different temperature
Product Temp.(°C)
% of P.L.C at Different
Tem
H.A.L.C.C 110°c -0.04
H.A.L.C.C 400°c -0.12
H.A.L.C.C 600°c -0.07
H.A.L.C.C 800°c -0.09
H.A.L.C.C 1000°c -0.62
H.A.L.C.C 1200°c -0.09
H.A.L.C.C 1300°c -1.24
H.A.L.C.C 1400°c -1.29
H.A.L.C.C 1500°c -2.12
% OF P.L.C FOR H.A.L.C.C
-0.04
-0.12 -0.07 -0.09
-0.62
-0.09
-1.24 -1.29
-2.12
-2.50
-2.00
-1.50
-1.00
-0.50
0.00
110°c 400°c 600°c 800°c 1000°c 1200°c 1300°c 1400°c 1500°c
TEMPERATURE
%
OF
P.L.C
H.A.L.C.C-HIGH ALUMINA LOW CEMENT CASTABLE

33. 33
LOSS ON IGNITION (L.O.I): the loss of weight due to applying
temperature is known as loss on ignition. It is due to the evaporation of
volatile matter, chemically combined water and the combustion of
carbonaceous matter present in the materials and also splitting of some
L.O.I products present in the material from dry to fired state.
Procedure: this test can be determined by as follows.Is to weigha sample
of the material(W1),then it is fired in 1000oc.after completion of firing
the sample of the material is cooled to room temprature then re-
weigh(W2). Result can be calculated as follows.
Formula:
Dry weight (W1)-fired weight (W1)
% Of L.O.I = X 100
Dry weight (W1)
 Loss on ignition depends upon the volatile matter present in the
material. If volatile matter is high the value of LOI also high.
MODULUS OF RUPTURE (MOR): the cross bending strength
of the material is known as modulus of rupture. The specimens are
already water cured and then dried those samples at 110ºc in drier. After
we check CCS and MOR.
PROCEDURE: For determination of MOR prepare the test specimens
(160mmx40mmx40mm) and those are water cured and dried at 110ºc/24
hours. Before testing specimen dimensions are measured (length, width

34. 34
and height) the specimens used in this three point loading test. the
distance between the bearing edge 12.5cm.the test specimen is placed on
two points and load is gradually applied from the top. Load apply is stop
after breaking of test piece. Continued for all specimens. The calculation
as follows.
MOR (in kg/cm2) = 102*3PL/2BD2
Where.
102=this is the factor convert to the value from KN to KG.
P=at which load the specimens failed.(load in KN).
L=distance between two supports is 12.5cm s.
B=breadth of specimens in centimeter in cm s.
D=depth of the specimen in cm s.
CONCLUSION: this test gives an idea about modulus strength of the
refractory materials
Product Temp.(°C) M.O.R (kg/cm2)
H.A.L.C.C 110°c 144
H.A.L.C.C 400°c 130
H.A.L.C.C 600°c 122
H.A.L.C.C 800°c 109
H.A.L.C.C 1000°c 115
H.A.L.C.C 1200°c 123
H.A.L.C.C 1300°c 194
H.A.L.C.C 1400°c 138
H.A.L.C.C 1500°c 122
.

35. 35
M.O.R (kg/cm2)
144
130 122
109 115 123
194
138
122
0
50
100
150
200
250
110°c 400°c 600°c 800°c 1000°c 1200°c 1300°c 1400°c 1500°c
TEMPERATURES
(kg/cm2)
HOT MODULUS OF RUPTURE: Modulus of rupture of a
product at elevated temperature is known as HMOR
PROCEDURE:
The specimens used in this three point loading test are usually
approximately 15cmx2.5cmx2.5cm. The dimensions are noted (breadth
(b), height (d)). The distance between the bearings edges is
approximately 10 cm. Load is applied at the middle. Maximum six
specimens can be placed in furnace. Some space is arranged between the
specimens. The temperature is taken by means of a thermo couple. After
placing of test pieces the door is closed and arrange program for elevated
temperature. Then reaches the elevated temperature allow for two hours.
Soaking is completed then the piece is adjusted by pushing of rods. Then
display is switched on. When the sample in position indication is shows
as the sample is on position then stop the pushing. After that adjust the
display reading to zero. Then load is applied gradually at a rate of 2.8 kg
per sec. Then the constant result is in kg s. automatically the result is
display on the screen by visually. After failure of test piece remove and

36. 36
adjust or push the next specimen to be tested. Then sample procedure is
continued for all specimens. The calculation is as follows.
The hot MOR (kg/cm2) is calculating from the following formula.
3PL/2BD2
P=Applying load (kg s)
L= Distance between the two supports of the test piece. (12.5cm s)
B= breadth of the specimen (in cm s)
D= depth or height of specimen (in cm s)
OR
LOAD X18.75
B*D2
HOT MODULES OF RUPTURE OF HIGH ALUMINA LOW CEMENT
CASTABLS.
PRODUCT BREDTH(b) DEPTH(d) LOAD( IN KG S) H.M.O.R(kg/cm2)
60%H.A.L.C.C. 2.692 2.55 31.6 33.77
70%H.A.L.C.C. 2.788 2.576 13.89 14.077
80%H.A.L.C.C. 2.645 2.565 11.5 12.39
95%H.A.L.C.C. 2.644 2.57 157.7 169.31

37. 37
H.M.O.R(kg/cm2)
33.77
14.077 12.39
169.31
0
20
40
60
80
100
120
140
160
180
60%H.A.L.C.C. 70%H.A.L.C.C. 80%H.A.L.C.C. 95%H.A.L.C.C.
(KG/CM2)
H.M.O.R(kg/cm2)
COLD CRUSHING STRENGTH: Load-bearing strength of a
product in cold condition is known as cold crushing strength. C.C.S is
depending upon particle packing and composition of a product.
PROCEDURE:
Half pieces are obtained after determination of MOR. The test piece
shall be a specimen of (80mmx40mmx40mm). Each half piece shall be
tested for compressive strength by applying load on it top face over an
area of 40mmx40mm.piece shall be placed between the two hard plates.
Hard plates are made with steel or tungsten carbide. Half test pieces are
sand witched between the two plates. It should place at the center.
Change the device and scale for our requirements. Then load is applied
from the top surface, load is applied gradually by using hydraulic
pressure. After failure of test specimen the applying of load is stop and
then note down the readings. This procedure is followed for all
specimens. A unit of CCS is in KN.
CONCLUSION: CCS also depends upon the composition of the product
and particle size.

38. 38
Ex: low cement Castable has very more compactness and 5-6% lime
content so achieving higher strength and high bulk density.
CALCULATION: The compressive strength is calculated from the
formula is
CCS (in kg/cm2) = Load*102
Area
102 =this is converts the value from KN to KG
Load =load in KN
Area =length x breadth.
Product Temp.(°C) C.C.S(kg/cm2)
H.A.L.C.C 110°c 874
H.A.L.C.C 400°c 826
H.A.L.C.C 600°c 832
H.A.L.C.C 800°c 932
H.A.L.C.C 1000°c 1124
H.A.L.C.C 1200°c 1028
H.A.L.C.C 1300°c 1174
H.A.L.C.C 1400°c 1273
H.A.L.C.C 1500°c 1272
C.C.S AND MOR OF HIGH ALUMINA LOW CEMENT CASTABLE

39. 39
C.C.S AND M.O.R AT 1000 °C FOR DIFFERANT PRODUCTS
131 169 115 138 120 86
1144
788
1124
1024
938
445
0
200
400
600
800
1000
1200
1400
9
0
%
H
.
A
.
L
.
C
.
C
8
0
%
H
.
A
.
L
.
C
.
C
7
0
%
H
.
A
.
L
.
C
.
C
6
0
%
H
.
A
.
L
.
C
.
C
5
0
%
H
.
A
.
L
.
C
.
C
4
5
%
H
.
A
.
L
.
C
.
C
HIGH ALUMINA LOW CEMENT CASTABLES
RESULT
IN
(kg/cm2)
M.O.R AT 1000°C
C.C.S AT 1000°C
THERMAL CONDUCTIVITY: thermal conductivity means
conductivity of heat from one surface to another surface by means of
conduction. Thermal conductivity test is done to determine the thermal
conductivity of a refractory material. Thermal conductivity mainly
depends upon the particles packing. Not only particles packing but also
mainly depend upon the porosity of the Refractory.
For the determining of thermal conductivity the following procedure will
be followed.
PROCEDURE: (this test process based on ASTM C-202 AND 417.)
S.NO PRODUCTS M.O.R AT 1000°C C.C.S AT 1000°C
1 90%H.A.L.C.C 131 1144
2 80%H.A.L.C.C 169 788
3 70%H.A.L.C.C 115 1124
4 60%H.A.L.C.C 138 1024
5 50%H.A.L.C.C 120 938
6 45%H.A.L.C.C 86 445

40. 40
 Making of standard brick with grooves for taking a known amount
of material.Then drying for 24 hours.
 Before conducting the test the specimen will be fired at 1000c
 Measure the test dimensions of (length, width and height)
specimen in (centimeters)
 Kept the specimen in heating chamber and put the thermometer
slab on it and then cover the space around the brick with ceramic
fiber.
 Keep the cold face thermocouple in the groove and cover the tip of
the thermocouple with powder of the same material of the test
specimen. This is to avoid contact between the tip of the cold face
thermocouple and the bottom of the calorimeter.
 Start the furnace and then set the elevated temperature.
 Keep the corner calorimeter assembly over the test specimen and
start the flow of water through the calorimeter. Adjust the flow of
water through calorimeter, as one liter of water is flow with in one
minute.
 The inlet flow should maintain 120-200 ml per min into center face
calorimeter.
 When the hot face temperature reaches to set temperature then we
keep 2hours soaking .Then we take the readings in Evart 30 min
 For calculating the thermal conductivity result we take hot face
temperature and could face temperatures and take how much water
flow going into the center calorimeter per min. we also take water
in let temperature and out let water temperature of center face
calorimeter and also area of the test piece and thickness of the slab
by using this readings and temperatures we can get result easily.

41. 41
CALCULATION:
Thermal conductivity = [q L/A (t1-t2)]
q= temperature difference between in let water temperature and
out let temperature of center calorimeter multiples with * the water flow
in to the center calorimeter in 1sec
L=thickness of the test slab in (cm)
A=area of the central calorimeter in cm2 (7.6*7.6=57.76)
t1= hot face temperature.
t2=could face temperature
t1-t2=temperature difference between the hot face and could face .
Thermal conductivity = [q L/A (t1-t2)] cal/cm/0c/sec
This valve converted in to K=W/m .k for converting we multiples
with 418.4 then we get result in watts per meter Kelvin.
Example for the calculation of this test by using insulation product:-
Thermal conductivity =q l/A (t1-t2) value in cal per sec/cm x *c
q =temperature difference between in let and out
let water x water flow into the centre calorimeter in 1sec.
TCO=In let water 32.3*c.
TW= out let water 33.7
Tem .difference =1.4
Water flow in center calorimeter per minute =190
q =1.4 x190/60
q =4.43
Thickness of the sample is 5.14 in cm s.
Area of the calorimeter 7.6 x7.6 =57.76 in cm s.
t 1=hot face temperature 516*c
t 2=could face temperature 94*c
t= (t1 –t2) = 422*c
T.C= 4.43 X 5.14 / 57.76 X 422
T.C=0.0009342 in cal x sec/cm x *c.
This value converts into K= W/m. k in watts per meter Kelvin.
The conversion factor from cal x sec/cm x *c to W/m. k is 418.4.
T.C in (W/m. k) =0.0009342 x 418.4
Thermal conductivity in (W/m. k) =0.39 W/m. k

42. 42
This are the low density products their thermal conductivity
PRODUCTS
AT 500°C
IT HAS
W/m.k
AT 800°C IT
HAS W/m.k AT 1000°C IT HAS W/m.k
INSULATION(PERALITE)
BASED 0.33 0.35 0.34
INSULATION product (grog
and bubble alumina) 0.34 0.29 0.26
INSULATION PRODUCT
(VERMICULITE&GROG)BASED 0.41 0.22 0.19
NO CEMENT CASTABLE 1.64
40%HIGH CEMENT CASTABLE 0.24 0.28 0.36
THERMAL CONDUCTIVITY FOR LOW DENSITYPRODUCTS
10.33 0.34 0.41
1.51
0.24
0.35 0.29
0.69
0.28
0.34 0.26
0.58
0.36
0.22
0.19
0
0.5
1
1.5
2
2.5
3
2 3 4 5
PRODUCTS
K=W/m.k
AT 1000°C IT HAS W/m.k
AT 800°C IT HAS W/m.k
AT 500°C HAS W/m.k

43. 43
This are the high density products their thermal conductivity
PRODUCTS
AT 500°C HAS
W/m.k
AT 800°C IT HAS
W/m.k
AT 1000°C IT HAS
W/m.k
Ultra low cement
castable 3.83 2.97 2.56
70% H.A.L.C.C 2.72 1.72 1.47
75%H.L.C.C 2.89 2.31 1.72
THERMAL CONDUCTVITY
3.83
2.97
2.56
2.72
1.72
1.47
2.89
2.31
1.72
0
1
2
3
4
5
6
7
8
9
10
AT 500°C HAS W/m.k AT 800°C IT HAS W/m.k AT 1000°C IT HAS W/m.k
TEMPERATURES
VALUE
IN
K=W/m.k
DURAFLOW 75Z
CR6070 STD
CR6070 L
SPALLING RESISTANCE:
Resistance to fractures or cracking of refractory by sudden change in
temperature is known as spalling resistance is also called as thermal
shock resistance.
PROCEDURE:
Prior the test specimens prepared by casting, water curing and
drying. The test conducted by any specimens. The test specimens shall
be used standard size of 230x115x65 mm or 230x115x75 mm. Spalling
is done by two methods one is water quenching and another is in air
quenching.
 IN WATER QUENCHING METHOD:
After firing to minimum at specified temperature remove the
sample from the furnace by the help of tongue or high temperature
withstanding cotton gloves and dip a deep of 1/3rd it in water. During this
water circulation should be continuing. After 05 minutes remove it from
water and keep in open air. Then again put it in the furnace. Continue
this procedure for number of specified cycles or till the sample getting
cracked and broken.

44. 44
 IN AIR QUENCHING METHOD:
In air quenching method after firing, to minimum at specified
temperature remove the sample from the furnace and keep it in air for ten
minutes. Then again put in the furnace for firing for next ten minutes
continue this procedure for number of specified cycles or till the sample
getting cracked and broken.
This test is conducted by air curing method. First the furnace will be start
and then set the specified temperature for the specified test specimens.
After reaching the temperature it will soaks around ten minutes. After
that with help of a tongue the bars are kept in the furnace. At a time
maximum one or two samples can be tested in this case when one sample
is in the furnace another one is out side of the furnace. One bar get inside
and outside is known as one cycle. This procedure is continued along for
the specified cycles. This procedure is followed for specified cycles.
After specified cycles it will cool it to room temperature. Then visually
examined.
Result:
The report shall include a note of the temperature used a umber of
complete cycles of heating and cooling required to promote fracture and
a note of the cycle during with cracks first appear together with a
description of the nature of the failure in which cycle.
Result for the following product:
Criterion 6085 xl(m)@1000o
c:
Cycle.no In-furnace Water Air Remarks
1 11.00 11.10 11.15 ---------
2 11.20 11.30 11.35 ---------
3 11.40 11.50 11.55 ----------
4 12.00 12.10 12.15 Hairline crack
5 12.20 12.30 12.35 ----------
6 12.40 12.50 12.55 ------------
7 01.00 01.10 01.15 ----------
8 01.20 01.30 01.35 Crack at corner
9 01.40 01.50 01.55 -----------

45. 45
10 02.00 02.10 02.15 -----------
11 02.20 02.30 02.35 Corner off
12 02.40 02.50 02.55 -----------
13 03.00 03.10 03.15 Big crack at corner
14 03.20 03.30 03.35 --------------
15 03.40 03.50 03.55 ---------------
16 04.00 04.10 04.15 Lengthy cracks at corners
17 04.20 04.30 04.35 --------------------
18 04.40 04.50 04.55 ---------------
19 05.00 05.10 05.15 -----------
20 05.20 05.30 05.35 -----------------
SPECIFIC GRAVITY: the specific gravity of the material is defined as
how many times of the density of the material is greater than compared
to the density of the water at 4c.
Specific gravity of the material = Density o the material
Density of water at 4c
BOTTLE METHOD:
Procedure:
The test depends on using the material in powder form together with a
density or specific gravity bottle. Fill the material 1/3rd of the bottle
volume. A capilary hole in the stopper of the bottle permits any excess of
liquid to be removed and at the same time gives the constant volume for
the bottle.in using the bottle care must be taken to see that no air bubbles
remain to the sides of the bottle.All weights are determined at constant
temprature.
Assuming that water/paraffin is used as liquid then the following
determinations must be made.
Where,
W1=weight of the specific gravity bottle

46. 46
W2= weight of the specific gravity bottle+powdered sample
W3= weight of the specific gravity bottle+powdered sample+water/paraffin
W4= weight of the specific gravity bottle+water/paraffin
Formulae for find out the specific gravity by bottle method:
=W2-W1
(W4-W1)-(W3-W2)
To determination of specific gravity of the material, by using specific
gravity bottle method. It has no units.
Equipments:
 Specific gravity bottle
 Weighing balance 0.1 gm accurately.
 Required material
Specific gravity of some raw materials
MATERIALS M-1 M-2 M-3 M-4 SP GRAVITY
1.SIC 200 31.99 71.52 110.23 83.14 3.18
2.HG 90 CLAY 31.98 50.12 93.77 83.13 2.42
3.SBA 48 31.99 79.40 117.32 83.13 3.59
4.POLYCEM 75 32.04 57.60 99.60 83.13 2.81
5.SECAR 71 31.99 49.98 94.89 83.13 2.89
6.SECAR 80 32.04 46.21 92.80 83.13 3.15
7.REFCON MG 32.15 45.79 91.96 83.13 2.84
8.CALCEM 50 32.04 51.64 95.98 83.13 2.90

47. 47
9.ALMAG 70 32.24 42.58 89.89 83.13 2.89
10.CA 25 AR 32.10 41.40 89.59 83.13 3.27
11.QUARTZ PO
WDER 31.99 67.23 104.51 83.13 2.54
12.SKB 200 32.06 45.31 92.73 83.13 3.63
13.MR 301 32.11 46.81 94.02 83.13 3.86
14.HGRM 30 32.23 41.42 89.96 83.13 3.89
15.QKV 325 A 32.15 46.02 93.07 83.13 3.53
16.QKV 100 F 32.17 46.82 93.63 83.13 3.53
17.LF 0-1 32.26 47.79 94.46 83.13 3.70
18.GG 0-1 32.37 47.67 94.27 83.13 3.68
19.INSULATING GROG
0-1 32.24 52.49 95.94 83.13 2.72
20.QGV 955 D 32.43 41.86 86.65 83.13 1.60
21.MLK 200 32.23 47.27 93.02 83.13 2.92
22.AND FINES 32.23 44.11 91.27 83.13 3.18
PYROMETRIC CONE EQUIVALENT (P.C.E): the test is done to
determine the refractoriness of a material. It is the measure of fusibility
of material.
A representative sample of material to be tested is ground to pass
through ASTM 70#. The magnet iron is removed by using permanent
magnet. After demagnetization add some organic binder like dextrin and
mixed thoroughly. Then add water to form a paste. Then apply this paste
on the PCE cone mould to form a cone of dimensions 25mm height and
8mm base. Then dry the mould at 110c for 2-3 hours. Now the
specimen is ready to be conduct the PCE test.Mount the test piece on the

48. 48
refractory plaque. The plaque may be circular or rectangular, square
depending upon the design of the furnace. Fix the specimen using high
temperature binding material. Surrounding to this cone put some
standard cones of known melting temperature.
Put this inside of the furnace and switch on it, then increase the current
supply there by the furnace temperature will increase. The test shall be
continued till the test cone get bent under its own weight and touch the
base of the plaque bearing the specimen. The refractoriness shall be
reported as the number of the pyrometric cone that has bents over to
similar extent to the test cone.
Shall be reported as laying between the two cone numbers in the event of
test piece not bending manner an indication of the type of cone number
at which occurs shall be given.
Conclusion: PCE test gives an idea about the refractoriness of a material.
APPARENT POROSITY, BULK DENSITY AND WATER
ABSORPTION OF MONOLITHIC PRODUCTS AND
MATERIALS:
POROSITY:
Porosity is the ratio between the volume of the pore space and total
volume of the specimen. Porosity can calculate in percentage.
APPARENT POROSITY:
It is the ratio of the volume of open pores to the bulk volume of the
material. Units can be calculated in percentage.

49. 49
Procedure: For Water Boiling Method:
The given test sample is dried at 110c in electrical drier about 1-2
hours. After drying the weight of specimen is taken, known as dry
weight (d) Gms. Take a glass beaker with about 3/4th of water and place
it above the electrical heater. Then put the samples in the beaker by
hanging it on a glass rod with the help of flexible thread. After that
switch on the heater. Boil the samples for 2 hours. After boiling, the
sample is allowed to cool for some time then removed it from the beaker.
Remove the wetness of the sample by using dry cloth. Now take the
weight of the sample known as soaked weight (S) Gms. Then weighing a
glass beaker filled with water is placed at the bottom of the balance.
Then tied the sample with a thread and hang the sample on the hook.
Now the sample is weighed i.e. known suspended weight or immersed
weight (I) Gms of the test piece. From the below data density, apparent
porosity and water absorption is calculated.
Calculation:
Bulk density= mass/volume (D/S-I)
Apparent porosity = S-D x100
S-I
Water absorption = S-D x100
D
Where,
D=Dry weight of the specimen
S= soaked weight of the specimen
I= immersed weight of suspended weight
BULK DENSITY:
The relation ship between the mass and volume of a material is known as
density of material. The units of bulk density are gm/cc or kg/m3
Bulk density = Mass
Volume

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Apparent porosity, bulk density and water absorption for some of
the raw materials:
MATERIAL D.W.T I.WT SO.WT B.D A.P W.B
1.MULLITE 11.63 7.45 11.72 2.72 2.11 0.77
2.SBA 3-6 18.96 13.72 19.05 3.56 1.69 0.47
3.TBC 3-5 10.81 6.71 10.95 2.55 3.30 1.30
4.QRF 2.5-3 10.33 7.48 10.52 3.40 6.25 1.84
5.LF 5-8 11.28 7.95 11.55 3.13 7.50 2.39
6.BFA 5-8 10.80 8.02 10.85 3.82 1.77 0.46
7.PMC3-5 7.94 4.98 8.16 2.50 6.92 2.77
8.WFA 3-6 7.47 5.49 7.64 3.47 7.91 2.28
9.INSULATING GROG 1-5 6.60 3.77 8.56 1.38 40.92 29.70
10.QRF 2.5-3 28.39 20.03 28.57 3.32 2.10 0.63
11.BALL CLAY@1450OC 38.41 21.20 42.59 1.79 19.54 10.88
LOOSE BULK DENSITY:(LBD)
It is the relationship between its mass and its unpacked volume of the
material.
EQUIPMENTS:
 Weighing balance
 Conical funnel with stand
 Known volume of cylinder
PROCEDURE:
 Keep the cylinder directly at the bottom of the funnel
 Close the opening of the funnel and then take some material and
put into the funnel
 Then open the closed lid of the funnel
 Then allow the material fall freely in to the cylinder under the
force of gravity.
 Remove the excess material without shaking
 Then weigh the material.
Calculation:
LBD = Mass

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VOLUME
LOW CEMENT
CASTABLE (70%). Gm/cc
PRODUCT LBD
45%H.A.C.C 1.36
50% H.A.C.C 1.44
60%H.A.C.C 1.74
70%H.A.C.C 1.76
80%H.A.C.C 1.78
90%H.A.C.C 1.86
METERIAL LBD(gm/cc)
POLYCEM-75 0.96
CA25R 0.8
REFCEM 60 0.97
SECAR 68V 0.93
SECAR-71 0.84
CALCEM-50 1.06
SECAR 80 0.8
PMC 0-1 1.38
PMC FINES 0.87
BALL CLAY 0.56
BENTONITE 0.72
FELDSPAR 0.89
FLYASH 0.8
VERMICULATE 0.27
INSULATING GROG 0-6 0.67
INSULATING GROG 0-1 0.78
PERLITE 0-3 0.14
PERLITE 0-1 0.1
HGRM 30 0.87
SKB-200 1.44
E-SPHERE 0.4
OPC 0.95

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DETERMINATION OF WATER OF CONSISTENCY OF
CEMENT:
Take the 300 Gms of sample and place it in a cool place. It will
be comes to ambient temperature. Add about 28% of water and mix it
thoroughly by using trowel. Place it in a vicat apparature mould and
tap it for uniform surface. Fix the consistency plunger and on the
surface of paste and release. Take the reading when the pointer should
be in between 5-7. That is the water of consistency of cement.
DETERMINATION OF SETTING TIME OF CEMENT:
Take the 300gms of sample and place it in a cool place. It will
be comes to ambient temperature. Add about 85% of water to the
water of consistency of cement and mix it thoroughly by using trowel.
Place it in a vicat apparatus mould and tap it for uniform surface. Fix
the Initial setting time needle bottom of the vicat apparatus and on the
surface of the paste and then release the needle. Take the reading and
the reading should be 5 +1. That is initial setting time of that of
cement. And then release the initial setting time needle on the surface
of the sample and release. Note down the time when needle makes an
impression. While the impression fails and is the final setting time of
cement.
Conclusion:
Setting time of cement depends up on the phases of that
cement and alumina content of that cement.

53. 53
TEST PROCEDURE OF ABRASION RESESTINCE TEST:-
 This test is used for calculate the abrasion resistance to our
required refractory products.
 This test process is based on the A S T M -C-704
 Test Specimen Dimensions should maintain as like this
114mm*114mm*65mm like cube.
 After prepared sample has to dry for 24 hours. After then the
sample has fired our required temperature like 500°c, 800°c1000°.
The firing socking time should maintain more then 180 min.
 After that firing we take dimensions of the test piece then based on
the initial dimensions and weight we can calculate the density of
piece.
 The abrasion testing machine has to prepare for the test.
 The Silicon carbide grains have to prepare for the test as for the
A.S.T.M. Standards like having the following screen analysis.
+20# -trace
+30# -20+/-2 %
+50#- 80+/-3%

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+70#- 2%maximum
 The feeding of grains in abrasion media has tow funnels .the
funnels containing suitable orifice that one has approximately
4.5mm diameter to obtain a flow time of 450+/-15 seconds for
1000gm of abrasion grains.
 Before testing the piece determine the density and initial weight.
After then the test specimen place in abrasion chamber at
accurately 90° degree angle to the glass nozzle.
 The distance between glass nozzle to test sample has should
maintain 8inches (203mm).the flint glass tube length have
115mm and out side diameter have 7mm.innerside diameter
have 5.9mm.
 The glass tube is attached to steel pipe by using pack tope again
that held in place by a 70mm long piece of stain less steel tube.
The small 2mm distance should maintain between the glass tube
to pressure line steel line tube.
 The pressure should maintain 65psi.then we should check the
air pressure before and after abrasion media is run in the system.
 After then maintain the constant vacuum pressure at 15mmhg
by using reading scale and by adjusting the glass tube.
 For feeding the abrasion media we use two funnels that funnel
must contain a suitable orifice to obtain a flow time has 450+/-
15 sec while delivering 1000grams.plastic orifice can use for
maintain the flow.
 Then we check distance between flint glass tub nozzle tip to test
specimen maintain 8 inches.
 After kept the piece close the chamber door with out air leek.
Then feed the silicon carbide grains in to the funnel.
 The vacuum gauge should maintain 15inHG.while testing air
pressure should maintain 65psi .before and after testing pressure
has to check.
 This 1000gm dry abrasion media delivered time of 450+/-15s
through out the funnel to pipe line that pipe line connects with
glass gunning nozzle then grain falls on the bar.

55. 55
 After complete that grains stop that air pressure then open that
chamber door and receive the test finished sample then we take
finial weight of the test piece.
 By using density and initial and finial weights we can calculate
the abrasion resistance result of test piece by as follows
calculation.
CALCULATION:-
A= [(W1-W2)/B]; A=W/B
Hear…
A=abrasion index in cc (cubic centimeter)
W1=initial weight of the test piece.
W2=finial weight of the test piece.
W=weight loss in (gm).
B=bulk density of the test specimen (gm/cc).
ABRASION RESISTANCE OF LOW CEMENT CASTABLE
AT 1000OC
PRODUCT ABRASION INDEX
CRITERION 6070M- 8.01
CRITERION 6070M- 7.01
CRITERION 6070L- 6.81
CRITERION 80 D- 3.72
CRITERION 6085 XL (M)- 3.60
CRITERION 80 DR- 4.53
CRITERION 6060 AS- 5.53
THERMAL EXPANSION TEST PROCEDURE:-
 Revisable Thermal explanation means how much expand
and contract the test body while firing at high temperatures.
 For testing these properties hear we use vertical dilatometer.
 This test is totally processing based on the personal
computer and dilatometer.
 The test piece shape has like a small rod the diameter of test
piece has 3.8mm and length of the specimen has 114mm.

56. 56
 The test piece should be smooth and note the
measurements before the use for the test.
 Then sample keep in to the furnace then piece is adjusts by
automatically. Then before the stating water supply should
be turned out .before starting set the maximum temperature
in personal computer and adds the dimensions of the test
piece .then set the 0 zero reading of the dilatometer.
 Then rise the temperature of the furnace by swatch on the
bottom swatch. The rate of increasing temperature is
5*c/min. the all reactions we get on X and Y ax ices of the
graph. By using graph we find the where the body was
expand and contract.
 The temperatures and expansion and contraction of the test
piece all results we easily get on the display of the P.C.
 After reached that maximum temperature then cool the
furnace 30*c/min .after few minutes we get all the results on
the display by use of graph. Then save the all results of the
test.
 Calculation -
Our required results we easily get in the test data
of the system.
Safety measures followed in each section of operation:
Monolithics:
Use of mask for the dust protection.
Use of safety gloves.
Use of helmets.
Use of eyes protective glasses
Use of hearing plugs
Use of safety shoes.

57. 57
Precast:
In this section also using same safety procedures as in the
monolithics.
Use of safety gloves
Use of earplugs during in grinding and casting
Laboratory:
Masks
Ear plugs and earmuff(sound protectives)
Using gloves
Using eyes protective glasses
Use of safety shoes
***THE END***

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